Sportage-2005-2006-2.0L

2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
2005-06 ENGINE
General - 2.0L - Sportage
GENERAL
SPECIFICATIONS
GENERAL SPECIFICATIONS
Description
General
Type
Number of cylinders
Bore
Stroke
Total displacement
Compression ratio
Firing order
Valve timing
Intake valve
Exhaust valve
Specifications (2.0 CVVT) Limit
In-line, DOHC
4
82mm (3.2283in)
93.5mm (8.6811 in)
1,975 cc (120.5 cu.in)
10.1: 1
1-3-4-2
Opens
(ATDC)
Closes
(ABDC)
Opens
(BBDC)
Closes
(ATDC)
11°
59°
42°
6°
Cylinder head
Flatness of gasket surface
Intake
Flatness of manifold mounting surface
Exhaust
STD
Valve guide hole diameter (Intake,
Exhaust)
0.05 OS
0.25 OS
0.50 OS
STD
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08:34:11 a. m.
Less than 0.03mm
(0.0012in)
Less than 0.15mm
(0.0059in)
Less than 0.15mm
(0.0059in)
11.000 ~ 11.018mm
(0.4331 ~ 0.4338in)
11.050 ~ 11.068mm
(0.4350 ~ 0.4357in)
11.250 ~ 11.268mm
(0.4429 ~ 0.4436in)
11.500 ~ 11.518mm
(0.4528 ~ 0.4535in)
33.000 ~ 33.025mm
(1.2992 ~ 1.3002in)
Page 1
0.06mm
(0.0024in)
0.30mm
(0.0118in)
0.30mm
(0.0118in)
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
0.3 OS
Intake valve seat ring hole diameter
0.6 OS
STD
Exhaust valve seat ring hole diameter
0.3 OS
0.6 OS
GENERAL SPECIFICATIONS
Description
Camshaft
Intake
Cam height
Exhaust
Journal outer Diameter (Intake, Exhaust)
Bearing oil clearance
End play
33.300 ~ 33.325mm
(1.3110 ~ 1.3120in)
33.600 ~ 33.625mm
(1.3228 ~ 1.3238in)
28.500 ~ 28.521mm
(1.1220 ~ 1.1229in)
28.800 ~ 28.821mm
(1.1339 ~ 1.1347in)
29.100 ~ 29.121mm
(1.1457 ~ 1.1465in)
Specifications (2.0 CVVT)
44.518 ~ 44.718mm
(1.7527 ~ 1.7605in)
44.418 ~ 44.618mm
(1.7487 ~ 1.7566in)
27.964 ~ 27.980mm
(1.1009 ~ 1.1016in)
0.02 ~ 0.061mm
(0.0008 ~ 0.0024in)
0.10 ~ 0.20mm
(0.0039 ~ 0.0079in)
Limit
0.1mm (0.0039in)
Valve
Valve length
Intake
Exhaust
Intake
Stem outer diameter
Exhaust
Face angle
Thickness of Valve
head (margin)
Valve stem to Valve
guide clearance
Intake
Exhaust
Intake
Exhaust
114.34mm (4.5016in)
116.8mm (4.5984in)
5.965 ~ 5.980mm
(0.2348 ~ 0.2354in)
5.950 ~ 5.965mm
(0.2343 ~ 0.2348in)
45° ~ 45°30'
1.15mm (0.0453in)
1.35mm (0.0531 in)
0.020 ~ 0.050mm
(0.0008 ~ 0.0020in)
0.035 ~ 0.065mm
(0.0014 ~ 0.0026in)
0.8mm (0.0315in)
1.0mm (0.0394in)
0.10mm
(0.0039in)
0.13mm (0.0051
in)
Valve guide
Intake
Length
Exhaust
45.8 ~ 46.2mm
(1.8031 ~ 1.8189in)
54.3 ~ 54.6mm
(2.1378 ~ 2.1496in)
Valve seat
domingo, 7 de febrero de 2021 08:34:12 a. m.
Page 2
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Intake
Width of seat contact
Exhaust
Seat angle
Intake
Exhaust
Valve spring
Free length
48.86mm (1.9236in)
18.8+/-0.9kg/39.0mm
(41.4+/-2.0 lb/1.5354in)
41.0+/-1.5kg/30.5mm
(90.4+/-3.3 lb/1.2008in)
Less than 1.5°
Load
Out of squareness
Valve clearance
Cold (20°C +/- 5°C)
(68°F +/- 9°F)
1.1 ~ 1.5mm
(0.0433 ~ 0.0591 in)
1.3 ~ 1.7mm
(0.0512 ~ 0.0669in)
45° ~ 45°30'
45° ~ 45°30'
Intake
0.20mm (0.0079in)
Exhaust
0.28mm (0.0110in)
3°
0.12~0.28mm
(0.0047~0.0110in)
0.20~0.38mm
(0.0079~0.0150in)
Cylinder block
Cylinder bore
Flatness of gasket surface
82.00 ~ 82.03mm
(3.2283 ~ 3.2295in)
Total: Less than 0.05mm (0.0020in) Bore
to bore: Less than 0.03mm (0.0012in)
Piston
Piston outer diameter
Piston to cylinder clearance
No. 1 ring groove
Ring groove width
No. 2 ring groove
Oil ring groove
81.970 ~ 82.000mm
(3.2272 ~ 3.2283in)
0.020 ~ 0.040mm
(0.0008 ~ 0.0016in)
1.23 ~ 1.25mm
(0.0484 ~ 0.0492in)
1.22 ~ 1.24mm
(0.0480 ~ 0.0488in)
2.51 ~ 2.53mm
(0.0988 ~ 0.0996in)
Piston ring
Side clearance
No. 1 ring
No. 2 ring
Oil ring
No. 1 ring
End gap
No. 2 ring
Oil ring
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0.04 ~ 0.08mm (0.0016 ~ 0.0031 in)
0.03 ~ 0.07mm (0.0012 ~ 0.0028in)
0.06 ~ 0.15mm (0.0024 ~ 0.0059in)
0..23 ~ 0.38mm
(0.0091 ~ 0.0150in)
0.33 ~ 0.48mm
(0.0130 ~ 0.0189in)
0.1mm (0.0039in)
0.1mm (0.0039in)
0.2mm (0.0079in)
0.20 ~ 0.60mm
1.0mm (0.0394in)
Page 3
1.0mm (0.0394in)
1.0mm (0.0394in)
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
(0.0079 ~ 0.0236in)
Piston pin
Piston pin outer diameter
Piston pin hole inner diameter
Piston pin hole clearance
Connecting rod small end hole inner
diameter
Connecting rod small end hole clearance
Piston pin press-in load
20.001 ~ 20.006mm
(0.7874 ~ 0.7876in)
20.016 ~ 20.021mm
(0.7880 ~ 0.7882in)
0.010 ~ 0.020mm
(0.0004 ~ 0.0008in)
19.974 ~ 19.985mm
(0.7864 ~ 0.7868in)
-0.032 ~ -0.016mm
(-0.0013 ~ -0.0006in)
350~1,350 kg
(772~2,976 lb)
Connecting rod
Connecting rod big end inner diameter
Connecting rod bearing oil clearance
Side clearance
48.000 ~ 48.018mm
(1.8898 ~ 1.8905in)
0.024 ~ 0.044mm
(0.0009 ~ 0.0017in)
0.10 ~ 0.25mm
(0.0039 ~ 0.0098in)
0.4mm (0.0157in)
Crankshaft
Main journal outer diameter
Pin journal outer diameter
Main bearing oil clearance
End play
56.942 ~ 56.962mm
(2.2418 ~ 2.2426in)
44.946 ~ 44.966mm
(1.7695 ~ 1.7703in)
0.028 ~ 0.048mm
(0.0011 ~ 0.0019in)
0.06 ~ 0.260mm
(0.0024 ~ 0.0102in)
0.1mm (0.0039in)
0.3mm (0.0118in)
Flywheel
Runout
0.13mm (0.0051
in)
0.1mm (0.0039in)
Oil pump
Inner rotor
Side clearance
Outer rotor
Body clearance
Relief valve opening pressure
Free length
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0.040 ~ 0.085mm
(0.0016 ~ 0.0033in)
0.040 ~ 0.090mm
(0.0016 ~ 0.0035in)
0.120 ~ 0.185mm
(0.0047 ~ 0.0073in)
490+/-49.0kpa(5+/-0.5kg/cm2 , 71 +/-7.1
psi)
43.8mm (1.7244in)
3.7+/-0.4kg/40.1mm
Page 4
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Relief spring
(8.2+/-0.9 lb/1.5787in)
9.7+/-0.4kg/34.3mm
(21.4+/-0.9 lb/1.3504in)
Load
Engine oil
Oil quantity (Total)
Oil quantity (Oil pan)
Oil quantity (Oil filter)
Oil quality
Oil pressure (Idle)
Cooling system
Cooling method
Coolant quantity
Type
Opening
Thermostat
temperature
Pull opening
temperature
Main valve opening
pressure
Radiator cap
Vacuum valve
opening pressure
Water temperature sensor
Type
20°C (68°F)
Resistance
80°C (176°F)
4.0 L (4.23 US qt, 3.52 lmp qt)
3.7 L (3.91 US qt, 3.26 lmp qt)
0.3 L (0.32 US qt, 0.26 lmp qt)
Above SL, SJ
156.9kpa (1.6kg/cm2 , 22.8psi)
Forced circulation with cooling fan
6.0 L (6.34 US qt, 5.28 lmp qt)
Wax pellet type
82+/-1.5°C(179.6+/-2.7°F)
95°C (203°F)
93.16 ~ 122.58kpa
(0.95 ~ 1.25kg/cm2 , 13.51 ~ 17.78psi)
0.98 ~ 4.90 kpa
(0.01 ~ 0.05kg/cm2 , 0.14 ~ 0.71 psi)
Thermister type
2.45+/-0.14 kohm
0.3222 kohm
TIGHTENING TORQUE
TIGHTENING TORQUE SPECIFICATIONS
Item
Cylinder block
Engine support (front) bracket bolt
Engine support (rear) bracket bolt
Engine support bracket stay plate bolt
Engine mounting
Engine mounting bracket and body
fixing bolt
Engine mounting insulator and engine
mounting support bracket fixing nut
Engine mounting support bracket and
engine support bracket fixing bolt
Quantity
Tightening torque
N.m
kgf.m
lb-ft
3
2
1
34.3 ~ 49.0
34.3 ~ 49.0
42.2 ~ 53.9
3.5 ~ 5.0
3.5 ~ 5.0
4.3 ~ 5.5
25.3 ~ 36.2
25.3 ~ 36.2
31.1 ~ 39.8
3
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
1
58.8 ~ 78.5
6.0 ~ 8.0
43.4 ~ 57.9
1
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
domingo, 7 de febrero de 2021 08:34:12 a. m.
Page 5
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Engine mounting support bracket and
2
engine support bracket fixing nut
Transaxle mounting bracket and body
4
fixing bolt
Transaxle mounting insulator and
1
transaxle support bracket fixing bolt
Front roll stopper bracket and sub frame
3
fixing bolt
Front roll stopper insulator and front
roll stopper support bracket fixing bolt, 1
nut
Rear roll stopper bracket and sub frame
3
fixing bolt
Rear roll stopper insulator and rear roll
1
stopper support bracket fixing bolt, nut
Main moving system
Connecting rod cap nut
8
Crankshaft main bearing cap bolt
10
Flywheel bolt (M/T)
Drive plate bolt (A/T)
Timing belt
Timing belt upper cover bolt
Timing belt lower cover bolt
Timing belt under cover bolt
Crankshaft pulley bolt
Camshaft sprocket bolt
Timing belt tensioner bolt
Timing belt idler bolt
Cylinder head
Engine cover bolt
Cylinder head cover bolt
Camshaft bearing cap bolt
Exhaust camshaft and CVVT assembly
fixing bolt
Timing chain auto tensioner bolt
OCV (oil control valve) bolt
OCV (oil control valve) filter
Cylinder head bolt (10 X 99)
Cylinder head bolt (12 X 151)
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
88.3 ~ 107.9
9.0 ~ 11.0
65.1 ~ 79.6
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
6
6
49.0 ~ 52.0
27.5~31.4+60°
~64°
117.7 ~ 127.5
117.7 ~ 127.5
5.0 ~ 5.3
2.8~3.2+60°
~64°
12.0 ~ 13.0
12.0 ~ 13.0
36.2 ~ 38.3
20.3~23.1+60°
~64°
86.8 ~ 94.0
86.8 ~ 94.0
4
5
3
1
1
1
1
7.8 ~9.8
7.8 ~9.8
9.8 ~11.8
166.7 ~176.5
98.1 ~117.7
42.2 ~53.9
42.2 ~53.9
0.8 ~1.0
0.8 ~1.0
1.0 ~1.2
17.0 ~18.0
10.0 ~12.0
4.3 ~5.5
4.3 ~5.5
5.8 ~7.2
5.8 ~7.2
7.2 ~8.7
123.0 ~130.2
72.3 ~86.8
31.1 ~39.8
31.1 ~39.8
5
12
22
3.9 ~5.9
7.8 ~9.8
13.7 ~14.7
0.4 ~0.6
0.8 ~1.0
1.4 ~1.5
2.9 ~4.3
5.8 ~7.2
10.1 ~10.8
1
64.7 ~76.5
6.6 ~7.8
47.7 ~56.4
2
1
1
7.8 ~9.8
9.8 ~11.8
40.2 ~ 50.0
22.6~26.5+60°
~65°+60°~65°
27.5~31.4+60°
~65°+60°~65°
0.8 ~1.0
5.8 ~7.2
1.0 ~1.2
7.2 ~8.7
4.1 ~ 5.1
29.7 ~ 36.9
2.3~2.7+60° 16.6~19.5+60°
~65°+60°~65° ~65°+60°~65°
2.8~3.2+60° 20.3~23.1+60°
~65°+60°~65° ~65°+60°~65°
8
2
Cooling system
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Page 6
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Water pump pulley bolt
Water pump bolt (8 X 20)
Water pump bolt (8 X 35)
Water pump and alternator brace fixing
bolt (8 X 45)
Alternator brace and cylinder block
fixing bolt
Thermostat housing bolt
Thermostat housing nut
Water temperature sensor
Water inlet fitting nut
Lubrication system
Oil filter
Front case bolt (8 X 20)
Front case bolt (8 X 25)
Front case bolt (8 X 38)
Front case bolt (8 X 45)
Oil pan bolt (6 X 16)
Oil pan bolt (6 X 50)
Oil pan bolt (6 X 118)
Oil pan and transaxle fixing bolt
Oil pan drain bolt
Oil screen bolt
Oil pressure switch
Intake and exhaust system
Intake manifold and cylinder head
fixing nut
Intake manifold stay bolt
Exhaust manifold and cylinder head
fixing nut
O2 sensor to exhaust manifold
Exhaust manifold heat cover and
exhaust manifold fixing bolt
Air cleaner assembly fixing bolt
Throttle body and surge tank fixing bolt
Exhaust manifold and front muffler
fixing bolt
Front muffler fixing clip bolt
Front muffler and center muffler fixing
nut
Center muffler and main muffler fixing
nut
4
1
2
7.8 ~ 9.8
11.8 ~ 14.7
11.8 ~ 14.7
0.8 ~ 1.0
1.2 ~ 1.5
1.2 ~ 1.5
5.8 ~ 7.2
8.7 ~ 10.8
8.7 ~ 10.8
2
19.6 ~ 26.5
2.0 ~ 2.7
14.5 ~ 19.5
2
11.8 ~ 14.7
1.2 ~ 1.5
8.7 ~ 10.8
1
1
1
2
14.7 ~ 19.6
14.7 ~ 19.6
19.6 ~ 39.2
14.7 ~ 19.6
1.5 ~ 2.0
1.5 ~ 2.0
2.0 ~ 4.0
1.5 ~ 2.0
10.8 ~ 14.5
10.8 ~ 14.5
14.5 ~ 28.9
10.8 ~ 14.5
1
4
1
1
2
15
2
2
3
1
2
1
11.8 ~ 15.7
19.6 ~ 26.5
19.6 ~ 26.5
19.6 ~ 26.5
19.6 ~ 26.5
9.8 ~ 11.8
9.8 ~ 11.8
9.8 ~ 11.8
29.4 ~ 41.2
39.2 ~ 44.1
14.7 ~ 21.6
14.7 ~ 21.6
1.2 ~ 1.6
2.0 ~ 2.7
2.0 ~ 2.7
2.0 ~ 2.7
2.0 ~ 2.7
1.0 ~ 1.2
1.0 ~ 1.2
1.0 ~ 1.2
3.0 ~ 4.2
4.0 ~ 4.5
1.5 ~ 2.2
1.5 ~ 2.2
8.7 ~ 11.6
14.5 ~ 19.5
14.5 ~ 19.5
14.5 ~ 19.5
14.5 ~ 19.5
7.2 ~ 8.7
7.2 ~ 8.7
7.2 ~ 8.7
21.7 ~ 30.4
28.9 ~ 32.5
10.8 ~ 15.9
10.8 ~ 15.9
9
15.7 ~ 22.6
1.6 ~ 2.3
11.6 ~ 16.6
4
17.7 ~ 24.5
1.8 ~ 2.5
13.0 ~ 18.1
9
42.2 ~ 53.9
4.3 ~ 5.5
31.1 ~ 39.8
1
49.0 ~ 58.8
5.0 ~ 6.0
36.2 ~ 43.4
4
16.7 ~ 21.6
1.7 ~ 2.2
12.3 ~ 15.9
3
4
7.8 ~ 9.8
18.6 ~ 27.5
0.8 ~ 1.0
1.9 ~ 2.8
5.8 ~ 7.2
13.7 ~ 20.3
2
39.2 ~ 58.8
4.0 ~ 6.0
28.9 ~ 43.4
1
29.4 ~ 39.2
3.0 ~ 4.0
21.7 ~ 28.9
2
39.2 ~ 58.8
4.0 ~ 6.0
28.9 ~ 43.4
2
39.2 ~ 58.8
4.0 ~ 6.0
28.9 ~ 43.4
domingo, 7 de febrero de 2021 08:34:12 a. m.
Page 7
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
COMPRESSION PRESSURE INSPECTION
NOTE:
If the there is lack of power, excessive oil consumption or poor fuel economy,
measure the compression pressure.
1. Start the engine and allow to warm up to operating temperature (about five minutes).
Stop the engine.
2. Disconnect the ignition coil connectors and the spark plug cables.
Fig. 1: Disconnecting Ignition Coil Connectors And Spark Plug Cables
Courtesy of KIA MOTORS AMERICA, INC.
3. Remove the four spark plugs using a 16mm spark plug wrench.
4. Check the cylinder compression pressure.
1. Insert a compression gauge into the spark plug hole.
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Page 8
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 2: Checking Cylinder Compression Pressure
Courtesy of KIA MOTORS AMERICA, INC.
2. Fully open the throttle.
3. While cranking the engine, measure the compression pressure.
NOTE:
Always use a fully charged battery to obtain engine speed of 250rpm
or more.
4. Repeat step 1 through 3 for each cylinder.
NOTE:
This measurement must be done in as short a time as possible.
Compression pressure:
1,422kPa (14.5kg/cm2 , 206psi) (250~400 RPM)
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Page 9
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Minimum pressure:
1,275kPa (13.0kg/cm2 , 185psi)
Difference between each cylinder:
98kPa (1.0kg/cm2 , 14psi) or less
5. If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the
cylinder through the spark plug hole and repeat step 1 through 3 for cylinders with low
compression.
If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are
worn or damaged.
If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage
past the gasket.
5. Reinstall the spark plugs.
6. Connect the ignition coil connectors and the spark plug cables.
TIMING BELT TENSION ADJUSTMENT
1. Remove the engine cover.
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Page 10
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 3: Removing Engine Cover
Courtesy of KIA MOTORS AMERICA, INC.
2. Remove the RH front wheel.
3. Remove the bolts (B) and RH side cover (A).
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Page 11
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 4: Removing Bolts And RH Side Cover
Courtesy of KIA MOTORS AMERICA, INC.
4. Loosen the water pump pulley bolts.
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Page 12
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 5: Loosening Water Pump Pulley Bolts
Courtesy of KIA MOTORS AMERICA, INC.
5. Remove the alternator drive belt. (See CHARGING SYSTEM )
6. Remove the air conditioner compressor drive belt. (See DRIVE BELT )
7. Remove the power steering pump drive belt. (See CHECKING POWER STEERING BELT
TENSION )
8. Remove the water pump pulley.
9. Remove the 4 bolts (B) and timing belt upper cover (A).
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Page 13
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 6: Loosening Bolts And Timing Belt Upper Cover
Courtesy of KIA MOTORS AMERICA, INC.
10. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing belt cover. Check that
the timing mark of camshaft sprocket is aligned with the timing mark of cylinder head cover. (No.1
cylinder compression TDC position)
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Page 14
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 7: Aligning Crankshaft Pulley Groove Marks With Timing Belt Cover Timing Mark (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
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Page 15
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 8: Aligning Crankshaft Pulley Groove Marks With Timing Belt Cover Timing Mark (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
11. Remove the crankshaft pulley bolt (B) and crankshaft pulley (A).
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Page 16
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 9: Removing Crankshaft Pulley Bolt And Crankshaft Pulley
Courtesy of KIA MOTORS AMERICA, INC.
12. Remove the 5 bolts (B) and timing belt lower cover (A).
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Page 17
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 10: Removing Bolts And Timing Belt Lower Cover
Courtesy of KIA MOTORS AMERICA, INC.
13. Temporarily loosen the tensioner pulley (A) by center bolt.
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Page 18
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 11: Loosening Tensioner Pulley By Center Bolt
Courtesy of KIA MOTORS AMERICA, INC.
14. Adjust the timing belt tension.
1. Rotate the crankshaft clockwise (view from the front) through angle equivalent to two teeth (18°)
of camshaft sprocket (A).
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Page 19
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 12: Rotating Crankshaft Clockwise
Courtesy of KIA MOTORS AMERICA, INC.
2. Using a hex-wrench, apply tension to the timing belt in the clockwise direction so that there is no
slack in the belt on the tension side.
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Page 20
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 13: Applying Tension To Timing Belt
Courtesy of KIA MOTORS AMERICA, INC.
3. Tighten the tensioner bolt.
Tightening torque:
42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb-ft)
4. Recheck the belt tension. When applying about 5 lbs of force, the belt should move no more than
0.16 to 0.24 inch (4 to 6mm).
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Page 21
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 14: Rechecking Belt Tension
Courtesy of KIA MOTORS AMERICA, INC.
15. Turn the crankshaft two turns in the operating direction (clockwise) and realign the crankshaft sprocket
and camshaft sprocket timing mark.
16. Install the timing belt lower cover (A) with bolts (B).
Tightening torque:
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
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Page 22
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 15: Turning Crankshaft In Operating Direction
Courtesy of KIA MOTORS AMERICA, INC.
17. Install the crankshaft pulley (A) with bolt (B).
Tightening torque:
166.7 ~ 176.5N.m (17.0 ~ 18.0kgf.m, 123.0 ~ 130.2lb-ft)
domingo, 7 de febrero de 2021 08:34:12 a. m.
Page 23
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 16: Installing Crankshaft Pulley With Bolt
Courtesy of KIA MOTORS AMERICA, INC.
18. Install the timing belt upper cover (A) with bolts (B).
Tightening torque:
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
domingo, 7 de febrero de 2021 08:34:12 a. m.
Page 24
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 17: Installing Timing Belt Upper Cover With Bolts
Courtesy of KIA MOTORS AMERICA, INC.
19.
20.
21.
22.
23.
Install the water pump pulley.
Install the power steering pump drive belt. (See CHECKING POWER STEERING BELT TENSION )
Install the air conditioner compressor drive belt. (See DRIVE BELT )
Install the alternator drive belt. (See CHARGING SYSTEM )
Install the RH side cover (A) with bolts (B)
domingo, 7 de febrero de 2021 08:34:12 a. m.
Page 25
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 18: Installing RH Side Cover With Bolts
Courtesy of KIA MOTORS AMERICA, INC.
24. Install the RH front wheel.
Tightening torque:
88.3 ~ 107.9N.m (9 ~ 11kgf.m, 65.1 ~ 79.6lb-ft)
25. Install the engine cover (A) with bolts.
Tightening torque:
3.9 ~ 5.9N.m ( 0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)
domingo, 7 de febrero de 2021 08:34:12 a. m.
Page 26
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 19: Installing Engine Cover
Courtesy of KIA MOTORS AMERICA, INC.
VALVE CLEARANCE INSPECTION AND ADJUSTMENT
MLA (MECHANICAL LASH ADJUSTER)
NOTE:
Inspect and adjust the valve clearance when the engine is cold (Engine coolant
temperature: (20°C+/-5°C [68°F+/-9°F]) and cylinder head is installed on cylinder
block.
1. Remove the engine cover.
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Page 27
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 20: Removing Engine Cover
Courtesy of KIA MOTORS AMERICA, INC.
2. Remove the bolts (B) and timing belt upper cover (A).
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 21: Removing Timing Belt Upper Cover
Courtesy of KIA MOTORS AMERICA, INC.
3. Remove the cylinder head cover.
1. Disconnect the spark plug cables and do not pull on the cable by force.
NOTE:
Pulling on or bending the cables may damage the conductor inside.
domingo, 7 de febrero de 2021 08:34:12 a. m.
Page 29
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 22: Disconnecting Spark Plug Cables
Courtesy of KIA MOTORS AMERICA, INC.
2. Remove the PCV (Positive Crankcase Ventilation) hose (A) and the breather hose (B) from the
cylinder head cover.
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Page 30
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 23: Removing Positive Crankcase Ventilation Hose And Breather Hose From Cylinder
Head Cover
Courtesy of KIA MOTORS AMERICA, INC.
3. Remove the accelerator cable (A) from the cylinder head cover.
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2005-06 ENGINE General - 2.0L - Sportage
Fig. 24: Removing Accelerator Cable From Cylinder Head Cover
Courtesy of KIA MOTORS AMERICA, INC.
4. Loosen the cylinder head cover bolts (B) and then remove the cover (A) and gasket.
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 25: Removing Cylinder Head Cover And Gasket
Courtesy of KIA MOTORS AMERICA, INC.
4. Set No. 1 cylinder to TDC/compression.
1. Turn the crankshaft pulley and align its groove with the timing mark" T" of the lower timing belt
cover.
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Page 33
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 26: Aligning Crankshaft Pulley Groove Marks With Lower Timing Belt Cover Timing
Mark (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
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Page 34
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
2. Check that the hole of the camshaft timing pulley (A) is aligned with the timing mark of the bearing
cap.
If not, turn the crankshaft one revolution (360°).
Fig. 27: Aligning Crankshaft Pulley Groove Marks With Lower Timing Belt Cover Timing
Mark (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
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Page 35
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
5. Inspect the valve clearance.
1. Check only the valve indicated as shown. [No. 1 cylinder: TDC/compression]. Measure the valve
clearance.
Fig. 28: Inspecting Valve Clearance (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Using a thickness gauge, measure the clearance between the tappet shim and the base circle
of camshaft.
Record the out-of-specification valve clearance measurements. They will be used later to
determine the required replacement adjusting shim.
Valve clearance
[Specification]
Engine coolant temperature: (20°C +/- 5°C[68°F +/- 9°F])
Intake: 0.20mm (0.0079in)
Exhaust: 0.28mm (0.0110in)
[Limit]
Intake: 0.12 ~ 0.28mm (0.0047 ~ 0.0110in)
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Exhaust: 0.20 ~ 0.38mm (0.0079 ~ 0.0150in)
2. Turn the crankshaft pulley one revolution (360°) and align the groove with the timing mark "T" of
lower timing belt cover.
3. Check only valves indicated as shown. [No. 4 cylinder: TDC/compression]. Measure the valve
clearance. (See procedure step 1 )
Fig. 29: Inspecting Valve Clearance (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
6. Adjust the intake and exhaust valve clearance.
1. Turn the crankshaft so that the cam lobe of the camshaft on the adjusting valve is upward.
2. Using the SST(09220 - 2D000), press down the valve lifter and place the stopper between the
camshaft and valve lifter and remove the special tool.
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 30: Adjusting Intake And Exhaust Valve Clearance
Courtesy of KIA MOTORS AMERICA, INC.
3. Remove the adjusting shim with a small screw driver (A) and magnet (B).
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 31: Removing Adjusting Shim And Magnet
Courtesy of KIA MOTORS AMERICA, INC.
4. Measure the thickness of the removed shim using a micrometer.
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 32: Measuring Shim Thickness
Courtesy of KIA MOTORS AMERICA, INC.
5. Calculate the thickness of a new shim so that the valve clearance comes within the specified value.
Valve clearance
(Engine coolant temperature: 20°C +/- 5°C[68°F +/- 9°F])
T: Thickness of removed shim
A: Measured valve clearance
N: Thickness of new shim
Intake: N = T + [A - 0.20mm(0.0079in)]
Exhaust: N = T + [A - 0.28mm(0.0110in)]
6. Select a new shim with a thickness as close as possible to the calculated value. (Refer to Fig. 33
and Fig. 34 )
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Page 40
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
NOTE:
Shims are available in 20 size increments of 0.04mm (0.0016in) from
2.00mm (0.0787in) to 2.76mm (0.1087in)
7. Place a new adjusting shim on the valve lifter.
8. Using the SST(09220 - 2D000), press down the valve lifter and remove the stopper.
9. Recheck the valve clearance.
Valve clearance
(Engine coolant temperature: 20°C +/- 5°C[68°F +/- 9°F])
[Specification]
Intake: 0.20mm (0.0079in)
Exhaust: 0.28 mm (0.0110in)
[Limit] (After adjusting valve clearance)
Intake: 0.17 ~ 0.23mm (0.0067 ~ 0.0091 in)
Exhaust: 0.25 ~ 0.31mm (0.0098 ~ 0.0122in)
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Page 41
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 33: Adjusting Shim Selection Chart (Exhaust)
Courtesy of KIA MOTORS AMERICA, INC.
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Fig. 34: Adjusting Shim Selection Chart (Intake)
Courtesy of KIA MOTORS AMERICA, INC.
TROUBLESHOOTING
TROUBLESHOOTING
Symptom
Suspect area
Loose or improperly installed engine
flywheel.
Engine misfire with Worn piston rings.
abnormal internal
(Oil consumption may or may not cause the
lower engine noises. engine to misfire.)
Worn crankshaft thrust bearings.
Remedy
Repair or replace the flywheel as
required.
Inspect the cylinder for a loss of
compression.
Repair or replace as required.
Replace the crankshaft and bearings
as required.
Stuck valves.
(Carbon buildup on the valve stem can cause Repair or replace as required.
Engine misfire with the valve not to close properly.)
abnormal valve train
Replace the timing chain and
Excessive worn or mis-aligned timing chain.
noise.
sprocket as required.
Replace the camshaft and valve
Worn camshaft lobes.
lifters.
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
Faulty cylinder head gasket and/or
Inspect the cylinder head and
cracking or other damage to the
engine block for damage to the
Engine misfire with
cylinder head and engine block
coolant passages and/or a
coolant consumption
cooling system.
faulty head gasket.
Coolant consumption may or may not
Repair or replace as required.
cause the engine to overheat.
Worn valves, valve guides and/or valve stem
Repair or replace as required.
Engine misfire with oil seals.
excessive oil
Worn piston rings.
Inspect the cylinder for a loss of
consumption
(Oil consumption may or may not cause the compression
engine to misfire)
Repair or replace as required.
Drain the oil.
Incorrect oil viscosity.
Refill with the correct viscosity oil.
Engine noise on startup, but only lasting a
Inspect the thrust bearing and
few seconds.
Worn crankshaft thrust bearing.
crankshaft.
Repair or replace as required.
Low oil pressure.
Repair or replace as required.
Broken valve spring.
Replace the valve spring.
Worn or dirty valve lifters.
Replace the valve lifters.
Stretched or broken timing chain and/or
Replace the timing chain and
damaged sprocket teeth.
sprockets.
Upper engine noise, Worn timing chain tensioner, if applicable. Replace the timing chain tensioner
as required.
regardless of engine
Inspect the camshaft lobes. Replace
speed.
Worn camshaft lobes.
the camshaft and valve lifters as
required.
Inspect the valves and valve guides,
Worn valve guides or valve stems.
then repair as required.
Stuck valves. (Carbon on the valve stem or Inspect the valves and valve guides,
valve seat may cause the valve to stay open.) then repair as required.
Repair or replace damaged
Low oil pressure.
components as required.
Loose or damaged flywheel.
Repair or replace the flywheel.
Inspect the oil pan.
Damaged oil pan, contacting the oil pump
Inspect the oil pump screen.
screen.
Repair or replace as required.
Oil pump screen loose, damaged or
Inspect the oil pump screen.
restricted.
Repair or replace as required.
Inspect the piston and cylinder bore.
Excessive piston-to-cylinder bore clearance.
Repair as required.
Inspect the piston, piston pin and the
Excessive piston pin-to-bore clearance.
connecting rod.
Repair or replace as required.
Lower engine noise,
domingo, 7 de febrero de 2021 08:34:12 a. m.
Inspect the following components
Page 44
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
regardless of engine
speed.
and repair as required.
Excessive connecting rod bearing clearance.
The connecting rod bearings.
The connecting rods.
The crankshaft.
The crankshaft journal.
Inspect the following components
and repair as required.
Excessive crankshaft bearing clearance.
Incorrect piston, piston pin and connecting
rod installation.
Low oil pressure.
The crankshaft bearings.
The crankshaft journals.
Verify the piston pins and
connecting rods are installed
correctly.
Repair as required.
Repair or replace as required.
Inspect the following components
and repair as required.
Excessive connecting rod bearing clearance.
The connecting rod bearings.
The connecting rods.
The crankshaft.
Inspect the following components
and repair as required.
Excessive crankshaft bearing clearance.
The crankshaft bearings.
The crankshaft journals.
The cylinder block crankshaft
bearing bore.
Remove spark plugs and check for
fluid. Inspect for broken head gasket.
Inspect for cracked engine block or
cylinder head.
Inspect for a sticking fuel injector
and/or leaking fuel regulator.
Inspect timing chain and gears.
Repair as required.
Engine noise under
load.
Hydraulically locked cylinder.
Coolant/antifreeze in cylinder.
Oil in cylinder.
Fuel in cylinder.
Engine will not crank, Broken timing chain and/or timing chain
(crankshaft will not gears.
Foreign material in cylinder.
rotate)
Inspect cylinder for damaged
components and/or foreign materials.
Repair or replace as required.
Broken valve.
Piston material.
Foreign material.
Seized crankshaft or connecting rod
domingo, 7 de febrero de 2021 08:34:12 a. m.
Page 45
Inspect crankshaft and connecting
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2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
bearings.
Bent or broken connecting rod.
Broken crankshaft.
rod bearing.
Repair or replace as required.
Inspect connecting rods.
Repair or replace as required.
Inspect crankshaft.
Repair or replace as required.
SPECIAL SERVICE TOOLS
SPECIAL SERVICE TOOLS DESCRIPTIONS
Tool (Number and name)
Illustration
Use
Crankshaft front oil seal installer
Fig. 35 Installation of the front oil seal
(09214-32000)
Crankshaft front oil seal guide
Fig. 36 Installation of the front oil seal
(09214-32100)
Valve clearance adjust tool set
Fig. 37 Removal and installation of the
(09220-2D000)
tappet shim
Camshaft oil seal installer
Fig. 38 Installation of the camshaft oil
(09221-21000)
seal
Valve guide remover
Fig. 39 Removal and installation of the
(09221-3F100 (A))
valve guide
Valve guide installer
(09221-3F100 (B))
Valve stem oil seal installer
Fig. 40 Installation of the valve stem oil
(09222-22001)
seal
Valve spring compressor
Fig. 41 Removal and installation of the
(09222-28000)
intake or exhaust valve
Valve spring compressor adaptor
(09222-28100)
Crankshaft rear oil seal installer
Fig. 42 Installation of the crankshaft rear
(09231-21000)
oil seal
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2005-06 ENGINE General - 2.0L - Sportage
Fig. 35: View Of Crankshaft Front Oil Seal Installer
Courtesy of KIA MOTORS AMERICA, INC.
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Fig. 36: View Of Crankshaft Front Oil Seal Guide
Courtesy of KIA MOTORS AMERICA, INC.
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Fig. 37: View Of Valve Clearance Adjust Tool Set
Courtesy of KIA MOTORS AMERICA, INC.
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Fig. 38: View Of Camshaft Oil Seal Installer
Courtesy of KIA MOTORS AMERICA, INC.
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Fig. 39: View Of Valve Guide Remover
Courtesy of KIA MOTORS AMERICA, INC.
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Fig. 40: View Of Valve Stem Oil Seal Installer
Courtesy of KIA MOTORS AMERICA, INC.
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Fig. 41: View Of Valve Spring Compressor
Courtesy of KIA MOTORS AMERICA, INC.
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Fig. 42: View Of Crankshaft Rear Oil Seal Installer
Courtesy of KIA MOTORS AMERICA, INC.
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
2005-06 ENGINE
Cylinder Head Assembly - 2.0L - Sportage
COMPONENT
Fig. 1: Exploded View Of Cylinder Head Assembly Components (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
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08:32:59 a. m.
Page 1
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 2: Exploded View Of Cylinder Head Assembly Components (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
REMOVAL
Engine removal is not required for this procedure.
CAUTION:
Use Fender cover to avoid damaging painted surfaces.
To avoid damaging the cylinder head, wait until the engine coolant
temperature drops below normal temperature before removing it.
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Page 2
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
When handling a metal gasket, take care not to fold the gasket or
damage the contact surface of the gasket.
To avoid damage, unplug the wiring connectors carefully while
holding the connector portion.
NOTE:
Mark all wiring and hoses to avoid misconnection.
Inspect the timing belt before removing the cylinder head.
Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
1. Remove the air duct (A).
Fig. 3: Removing Air Duct
Courtesy of KIA MOTORS AMERICA, INC.
2. Disconnect the terminals (A) from battery.
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2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 4: Disconnecting Terminals From Battery
Courtesy of KIA MOTORS AMERICA, INC.
3. Remove the engine cover.
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 5: Removing Engine Cover
Courtesy of KIA MOTORS AMERICA, INC.
4. Drain the engine coolant. (Refer to ENGINE COOLANT REFILLING AND BLEEDING ) Remove
the radiator cap to speed draining.
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Fig. 6: Draining Engine Coolant
Courtesy of KIA MOTORS AMERICA, INC.
5. Remove the intake air hose and air cleaner assembly.
1. Disconnect the AFS (Air Flow Sensor) connector (A).
2. Disconnect the breather hose (B) from intake air hose.
3. Remove the intake air hose and air cleaner assembly (C).
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Page 6
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 7: Removing Intake Air Hose And Air Cleaner Assembly
Courtesy of KIA MOTORS AMERICA, INC.
6. Remove the upper radiator hose (A) and lower radiator hose (B).
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2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 8: Removing Upper And Lower Radiator Hose
Courtesy of KIA MOTORS AMERICA, INC.
7. Remove the heater hoses (A).
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Fig. 9: Removing Heater Hoses
Courtesy of KIA MOTORS AMERICA, INC.
8. Remove the accelerator cable (A) by loosening the lock-nut, then slip the cable end out of the throttle
linkage.
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Fig. 10: Removing Accelerator Cable
Courtesy of KIA MOTORS AMERICA, INC.
9. Remove the engine wire harness connectors and wire harness clamps from cylinder head and the intake
manifold.
1. Disconnect the OCV (Oil Control Valve) connector (A).
2. Disconnect the oil temperature sensor connector (B)
3. Disconnect the ECT (Engine Coolant Temperature) sensor connector (C).
4. Disconnect the ignition coil connector (D).
domingo, 7 de febrero de 2021 08:32:59 a. m.
Page 10
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 11: Disconnecting Ignition Coil Connector
Courtesy of KIA MOTORS AMERICA, INC.
5. Disconnect the TPS (Throttle Position Sensor) connector (A).
6. Disconnect the ISA (idle Speed Actuator) connector (B).
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 12: Disconnecting Idle Speed Actuator Connector
Courtesy of KIA MOTORS AMERICA, INC.
7.
8.
9.
10.
11.
Disconnect the CMP (Camshaft Position Sensor) connector (A).
Disconnect the four injector connectors (B).
Disconnect the knock sensor connector (C).
Disconnect the ground cables (D) from the intake manifold.
Disconnect the air conditioner compressor switch connector (E).
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2005 Kia Sportage EX
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Fig. 13: Disconnecting Air Conditioner Compressor Switch Connector
Courtesy of KIA MOTORS AMERICA, INC.
12. Disconnect the front heated oxygen sensor connector (A).
13. Disconnect the CKP (Crankshaft Position Sensor) connector (B).
14. Disconnect the oil pressure switch connector (C).
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Fig. 14: Disconnecting Oil Pressure Switch Connector
Courtesy of KIA MOTORS AMERICA, INC.
15. Disconnect the PCSV (Purge Control Solenoid Valve) connector (A).
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2005 Kia Sportage EX
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Fig. 15: Disconnecting Purge Control Solenoid Valve Connector
Courtesy of KIA MOTORS AMERICA, INC.
10. Disconnect the fuel inlet hose (A) of the delivery pipe side.
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Fig. 16: Disconnecting Fuel Inlet Hose Of Delivery Pipe Side
Courtesy of KIA MOTORS AMERICA, INC.
11. Disconnect the hose (A) of the PCSV (Purge Control Solenoid Valve) side.
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Fig. 17: Disconnecting Purge Control Solenoid Valve Side Hose
Courtesy of KIA MOTORS AMERICA, INC.
12. Remove the brake booster vacuum hose (A).
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Fig. 18: Removing Brake Booster Vacuum Hose
Courtesy of KIA MOTORS AMERICA, INC.
13. Remove the power steering pump drive belt.
14. Remove the power steering pump and fix the pump to vehicle with a wire. (See MECHANICAL
POWER STEERING SYSTEM ).
15. Remove the bolts (B, C) and power steering pump bracket (A).
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Fig. 19: Removing Power Steering Pump Bracket
Courtesy of KIA MOTORS AMERICA, INC.
16. Remove the spark plug cables.
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Fig. 20: Removing Spark Plug Cables
Courtesy of KIA MOTORS AMERICA, INC.
17.
18.
19.
20.
21.
22.
23.
Remove the exhaust manifold. (Refer to INTAKE AND EXHAUST SYSTEM - 2.0L )
Remove the intake manifold. (Refer to INTAKE AND EXHAUST SYSTEM - 2.0L )
Remove the timing belt. (Refer to REMOVAL , step 2-15)
Remove the PCV (Positive Crankcase Ventilation) hose.
Remove the cylinder head cover. (Refer to REMOVAL , step 18)
Remove the camshaft sprocket. (Refer to REMOVAL , step 19)
Insert a stopper pin or other device into timing chain auto tensioner and remove the auto tensioner.
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Fig. 21: Removing Auto Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
24. Remove the camshaft bearing caps (A) and camshafts (B).
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Fig. 22: Removing Camshaft Bearing Caps And Camshafts
Courtesy of KIA MOTORS AMERICA, INC.
25. Remove the OCV (Oil Control Valve) (A).
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Fig. 23: Removing Oil Control Valve
Courtesy of KIA MOTORS AMERICA, INC.
26. Remove the OCV (Oil Control Valve) filter (A).
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Fig. 24: Removing Oil Control Valve Filter
Courtesy of KIA MOTORS AMERICA, INC.
27. Remove the water hose (A) from water pipe (B).
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Fig. 25: Removing Water Hose From Water Pipe
Courtesy of KIA MOTORS AMERICA, INC.
28. Remove the cylinder head bolts, then remove the cylinder head.
1. Using 8mm and 10mm hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts,
in several passes, in the sequence shown. Remove the 10 cylinder head bolts and plate washers.
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Fig. 26: Removing Cylinder Head Bolts And Plate Washers
Courtesy of KIA MOTORS AMERICA, INC.
CAUTION: Head warpage or cracking could result from removing bolts in
an incorrect order.
2. Lift the cylinder head from the dowels on the cylinder block and replace the cylinder head on
wooden blocks on a bench.
CAUTION: Be careful not to damage the contact surfaces of the cylinder
head and cylinder block.
DISASSEMBLY
NOTE:
Identify MLA (Mechanical Lash Adjuster), valves, valve springs as they are
removed so that each item can be reinstalled in its original position.
1. Remove the MLAs (A).
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Fig. 27: Removing Mechanical Lash Adjuster
Courtesy of KIA MOTORS AMERICA, INC.
2. Remove the valves.
1. Using the SST (09222 - 28000, 09222 - 28100), compress the valve spring and remove the retainer
lock.
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Fig. 28: Compressing Valve Spring And Removing Retainer Lock
Courtesy of KIA MOTORS AMERICA, INC.
2.
3.
4.
5.
6.
Remove the spring retainer.
Remove the valve spring.
Remove the valve.
Using a needle-nose pliers, remove the oil seal.
Using a magnetic finger, remove the spring seat.
INSPECTION
CYLINDER HEAD
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block
and the manifolds for warpage.
Flatness of cylinder head gasket surface
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Standard: Less than 0.03mm (0.0012in)
Limit: 0.05mm (0.0020in)
Flatness of manifold mating surface
Standard: Less than 0.15mm (0.0059in)
Limit: 0.30mm (0.0118in)
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Fig. 29: Measuring Cylinder Block And Manifolds Warpage
Courtesy of KIA MOTORS AMERICA, INC.
2. Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If
cracked, replace the cylinder head.
VALVE AND VALVE SPRING
1. Inspect the valve stems and valve guides.
1. Using a caliper gauge, measure the inner diameter of valve guide.
Valve guide inner diameter:
6.000 ~ 6.015mm (0.2362 ~ 0.2368in)
Fig. 30: Measuring Valve Guide Inner Diameter
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Courtesy of KIA MOTORS AMERICA, INC.
2. Using a micrometer, measure the outer diameter of valve stem.
Valve stem outer diameter
Intake: 5.965 ~ 5.980mm (0.2348 ~ 0.2354in)
Exhaust: 5.950 ~ 5.965mm (0.2343 ~ 0.2348in)
Fig. 31: Measuring Valve Stem Outer Diameter
Courtesy of KIA MOTORS AMERICA, INC.
3. Subtract the valve stem outer diameter measurement from the valve guide inner diameter
measurement.
Valve stem- to-guide clearance
Standard
Intake: 0.020 ~ 0.050mm (0.0008 ~ 0.0020in)
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Exhaust: 0.035 ~ 0.065mm (0.0014 ~ 0.0026in)
Limit
Intake: 0.10mm (0.0039in)
Exhaust: 0.13mm (0.0051 in)
If the clearance is greater than maximum, replace the valve and valve guide.
2. Inspect the valves.
1. Check the valve is ground to the correct valve face angle.
2. Check the surface of the valve face for damage or wear.
If the valve face is damaged or worn, replace the valve.
3. Check the valve head margin thickness.
If the margin thickness is less than minimum, replace the valve.
Margin
Standard
Intake: 1.15mm (0.0453in)
Exhaust: 1.35mm (0.0531 in)
Limit
Intake: 0.8mm (0.0315in)
Exhaust: 1.0mm (0.0394in)
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Fig. 32: Checking Valve Head Margin Thickness
Courtesy of KIA MOTORS AMERICA, INC.
4. Check the surface of valve stem tip for wear. If the valve stem tip is worn, replace the valve.
3. Inspect the valve seats.
1. Check the valve seat for evidence of overheating and improper contact with the valve face.
Replace the seat if necessary.
2. Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace
it, then recondition the seat.
3. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should
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be within specifications and centered on the valve face.
Fig. 33: Reconditioning Valve Seat With Valve Seat Cutter
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Courtesy of KIA MOTORS AMERICA, INC.
4. Inspect the valve springs.
1. Using a steel square, measure the out-of-square of valve spring.
2. Using vernier calipers, measure the free length of valve spring.
Valve spring
Standard
Free height: 48.86mm (1.9236in)
Load: 18.8+/-0.9kg/39.0mm (41.4+/-2.0lb/1.5354in)
41.0+/-1.5kg/30.5mm (90.4+/-3.3lb/1.2008in)
Out of square: Less than 1.5°
Limit
Out of square: 3°
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Fig. 34: Measuring Valve Spring Free Length
Courtesy of KIA MOTORS AMERICA, INC.
If the loads is not as specified, replace the valve spring.
CAMSHAFT
1. Inspect the cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
Intake: 44.518 ~ 44.718mm (1.7527 ~ 1.7605in)
Exhaust: 44.418 ~ 44.618mm (1.7487 ~ 1.7566in)
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Fig. 35: Inspecting Cam Lobes
Courtesy of KIA MOTORS AMERICA, INC.
If the cam lobe height is less than minimum, replace the camshaft.
2. Inspect the camshaft journal clearance.
1. Clean the bearing caps and camshaft journals.
2. Place the camshafts on the cylinder head.
3. Lay a strip of plastigage across each of the camshaft journal.
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Fig. 36: Inspecting Camshaft Journal Clearance
Courtesy of KIA MOTORS AMERICA, INC.
4. Install the bearing caps and tighten the bolts with specified torque. (Refer to INSTALLATION ,
step 6 )
CAUTION: Do not turn the camshaft.
5. Remove the bearing caps.
6. Measure the plastigage at its widest point.
Bearing oil clearance
Standard: 0.020 ~ 0.061mm (0.0008 ~ 0.0024in)
Limit: 0.1mm ( 0.0039in)
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Fig. 37: Measuring Plastigage At Widest Point
Courtesy of KIA MOTORS AMERICA, INC.
If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing
caps and cylinder head as a set.
7. Completely remove the plastigage.
8. Remove the camshafts.
3. Inspect the camshaft end play.
1. Install the camshafts. (Refer to INSTALLATION step 6 )
2. Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play
Standard: 0.1 ~ 0.2mm (0.0039 ~ 0.0079in)
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Fig. 38: Inspecting Camshaft End Play
Courtesy of KIA MOTORS AMERICA, INC.
If the end play is greater than maximum, replace the camshaft. If necessary, replace the bearing
caps and cylinder head as a set.
3. Remove the camshafts.
CVVT (CONTINUOUS VARIABLE VALVE TIMING) ASSEMBLY
1. Inspect the CVVT (Continuous Variable Valve Timing) assembly.
1. Check that the CVVT (Continuous Variable Valve Timing) assembly will not turn.
2. Apply vinyl tape to all the parts except the one indicated by the arrow in the illustration.
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Fig. 39: Inspecting Continuous Variable Valve Timing Assembly
Courtesy of KIA MOTORS AMERICA, INC.
3. To release the CVVT lock pin, wrap some tape around the tip of an air pressure adapter and apply
low air pressure (About 14 psi) to the exposed camshaft port.
NOTE:
Wrap a shop towel or rag around the CVVT because residual oil may
leak out of the unit when applying air pressure.
4. With low air pressure applied, turn the CVVT to the ADVANCE direction as indicated in the
illustration.
With the low air pressure applied, the CVVT should turn to the ADVANCE side.
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If too much air leaks when applying the low air pressure, the CVVT lock pin may not release
and the CVVT may not turn.
Fig. 40: Identifying Continuous Variable Valve Timing Movement
Courtesy of KIA MOTORS AMERICA, INC.
5. Allow the CVVT assembly to move in the ADVANCE and RETARD directions to ensure there is
no binding and that it moves freely.
Standard: Movable smoothly in the range about 20°
6. Turn the CVVT by hand and make sure it locks in the maximum retard angle position.
REPLACEMENT
VALVE GUIDE
1. Using the SST(09221 - 3F100A), withdraw the old valve guide toward the bottom of cylinder head.
Fig. 41: Removing Valve Guide
Courtesy of KIA MOTORS AMERICA, INC.
2. Recondition the valve guide hole of cylinder head so that it can match the newly press-fitted oversize
valve guide.
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3. Using the SST (09221 - 3F100 A/B), press-fit the valve guide. The valve guide must be press-fitted from
the upper side of the cylinder head. Keep in mind that the intake and exhaust valve guides are different in
length.
Valve guide length
Intake: 45.8 - 46.2mm (1.8031 ~ 1.8189in)
Exhaust: 54.3 ~ 54.7mm (2.1378 ~ 2.1535in)
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Fig. 42: Installing Valve Guide
Courtesy of KIA MOTORS AMERICA, INC.
4. After the valve guide is press-fitted, insert a new valve and check for proper stem-to-guide clearance.
5. After the valve guide is replaced, check that the valve is seated properly. Recondition the valve seats as
necessary.
VALVE GUIDE OVERSIZE
VALVE GUIDE OVERSIZE SPECIFICATIONS
Oversize
Size
Valve guide hole inner
Item
[mm (in)]
mark diameter [mm (in)]
11.000 ~ 11.018 (0.4331
STD
~ 0.4338)
0.05 (0.002)
11.050 ~ 11.068 (0.4350
5
~ 0.4357)
Valve OS
guide 0.25 (0.010)
11.250 ~ 11.268 (0.4429
25
OS
~ 0.4436)
0.50 (0.020)
11.500 ~ 11.518
50
OS
( 0.4528 ~ 0.4535)
Valve guide outer
diameter [mm (in)]
11.040 ~ 11.050
(0.4346 ~ 0.4350)
11.090 ~ 11.100
(0.4366 ~ 0.4370)
11.290 ~ 11.300
(0.4445 ~ 0.4449)
11.540 ~ 11.550
(0.4543 ~ 0.4547)
Valve guide protrusion
height [mm (in)]
14.000 (0.5512)
VALVE SEAT RING
1. Cut away the inner face of the valve seat to reduce the wall thickness.
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Fig. 43: Identifying Valve Seat Ring Cutting Dimensions
Courtesy of KIA MOTORS AMERICA, INC.
2. Enlarge the seat ring hole of cylinder head so that matches the specified cylinder head hole inner diameter
of new valve seat ring.
3. Heat the cylinder head to about 250°C(480°F) and press-fit an oversize seat ring for the cylinder head
hole size.
4. Using lapping compound, lap the valve to the new seat.
VALVE SEAT RING OVERSIZE
VALVE SEAT RING OVERSIZE SPECIFICATIONS
Over size Size
Seat ring hole inner
Seat ring outer
Item
mm(in.)
mark diameter [mm(in)]
diameter [mm(in)]
33.000 ~ 33.025 (1.2992 33.090 ~ 33.105
STD
~ 1.3002)
(1.3028 ~ 1.3033)
Intake valve 0.3(0.012)
33.300 ~ 33.325 (1.3110 33.390 ~ 33.405
30
seat ring
OS
~ 1.3120)
(1.3146 ~ 1.3152)
0.6(0.024)
33.600 ~ 33.625 (1.3228 33.690 ~ 33.705
60
OS
~ 1.3238)
(1.3264 ~ 1.3270)
28.500 ~ 28.521 (1.1220 28.590 ~ 28.605
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Seat ring height
[mm(in)]
7.200 ~ 7.400
(0.2835 ~ 0.2913)
7.500 ~ 7.700
(0.2953 ~ 0.3031)
7.800 ~ 8.000
(0.3071 ~ 0.3150)
7.600 ~ 7.800
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
STD
0.3(0.012)
Exhaust valve
OS
seat ring
0.6(0.024)
OS
30
60
~ 1.1229)
(1.1256 ~ 1.1262)
28.800 ~ 28.821 (1.1339 28.890 ~ 28.905
~ 1.1347)
(1.1374 ~ 1.1380)
29.100 ~ 29.121 (1.1457 29.190 ~ 29.205
~ 1.1465)
(1.1492 ~ 1.1498)
(0.3110 ~ 0.3189)
7.900 ~ 8.100
(0.3110 ~ 0.3189)
8.200 ~ 8.400
(0.3228 ~ 0.3307)
REASSEMBLY
NOTE:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating
surface.
Replace oil seals with new ones.
1. Install the valves.
1. Install the spring seats.
2. Using the SST (09222 - 22001), push in a new oil seal.
NOTE:
Do not reuse old valve stem oil seals. Incorrect installation of the seal
could result in oil leakage past the valve guides.
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Fig. 44: Installing Valves
Courtesy of KIA MOTORS AMERICA, INC.
3. Install the valve, valve spring and spring retainer.
NOTE:
Place the valve springs so that the side coated with enamel faces
toward the valve spring retainer and then installs the retainer.
4. Using the SST(09222 - 28000, 09222 - 28100), compress the spring and install the retainer locks.
After installing the valves, ensure that the retainer locks are correctly in place before releasing the
valve spring compressor.
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Fig. 45: Compressing Spring And Installing Retainer Locks
Courtesy of KIA MOTORS AMERICA, INC.
5. Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to
ensure proper seating of the valve and retainer lock.
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Fig. 46: Tapping Valve Stem End
Courtesy of KIA MOTORS AMERICA, INC.
2. Install the MLA (Mechanical Lash Adjuster)s. Check that the MLA rotates smoothly by hand.
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Fig. 47: Installing Mechanical Lash Adjuster
Courtesy of KIA MOTORS AMERICA, INC.
INSTALLATION
NOTE:
Thoroughly clean all parts to be assembled.
Always use a new cylinder head and manifold gasket.
The cylinder head gasket is a metal gasket. Take care not to bend it.
Rotate the crankshaft, set the No. 1 piston at TDC.
1. Install the cylinder head gasket (A) on the cylinder block.
NOTE:
Be careful of the installation direction.
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Fig. 48: Installing Cylinder Head Gasket On Cylinder Block
Courtesy of KIA MOTORS AMERICA, INC.
2. Place the cylinder head onto the block carefully in order to prevent damaging the gasket. If the gasket is
damaged, fluid leakage could occur.
3. Install the cylinder head bolts.
1. Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
2. Using 8mm and 10mm hexagon wrench, install and tighten the 10 cylinder head bolts and plate
washers, in several passes, in the sequence shown.
Tightening torque:
M10: 22.6~26.5N.m (2.3~2.7kgf.m, 16.6~19.5lb-ft)+60°~65° + 60°~65°
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
M12: 27.5~31.4N.m (2.8~3.2kgf.m, 20.3~23.1 lb-ft)+60°-65° + 60°~65°
Fig. 49: Installing Cylinder Head Bolts
Courtesy of KIA MOTORS AMERICA, INC.
4. Install the OCV (Oil Control Valve) filter (A).
Tightening torque:
40.2 ~ 50.0N.m (4.1 ~ 5.1kgf.m, 29.7 ~ 36.9lb-ft)
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 50: Installing Oil Control Valve Filter
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
Always use a new OCV (Oil Control Valve) filter gasket.
Keep the OCV filter clean.
5. Install the OCV (Oil Control Valve) (A).
Tightening torque:
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 51: Installing Oil Control Valve
Courtesy of KIA MOTORS AMERICA, INC.
CAUTION:
Do not reuse the OCV (Oil Control Valve) when dropped.
Keep the OCV clean.
Do not hold the OCV (Oil Control Valve) sleeve during servicing.
When the OCV Is Installed on the engine, be careful not to rotate
the engine while holding the OCV.
6. Install the camshafts.
1. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain
sprocket as shown.
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2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 52: Aligning Camshaft Timing Chain With Intake And Exhaust Timing Chain Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
2. Install the camshaft (A) and bearing caps (B).
Tightening torque:
13.7 ~ 14.7N.m (1.4 ~ 1.5kgf.m, 10.1 ~ 10.8lb-ft)
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 53: Installing Camshaft And Bearing Caps
Courtesy of KIA MOTORS AMERICA, INC.
3. Install the timing chain auto tensioner (A).
Tightening torque:
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 54: Installing Timing Chain Auto Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
4. Remove the auto tensioner stopper pin (B).
7. Check and adjust valve clearance. (Refer to VALVE CLEARANCE INSPECTION AND
ADJUSTMENT )
8. Using the SST (09221 - 21000), install the camshaft bearing oil seal.
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 55: Installing Camshaft Bearing Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
9. Install the camshaft sprocket. (Refer to INSTALLATION , step 1)
10. Install the cylinder head cover.
1. Install the cylinder head cover gasket (A) in the groove of the cylinder head cover (B).
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 56: Installing Cylinder Head Cover Gasket In Cylinder Head Cover Groove
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
Before installing the cylinder head cover gasket, thoroughly
clean the cylinder head cover and the groove.
When installing, make sure the cylinder head cover gasket is
seated securely in the corners of the recesses with no gap.
2. Apply liquid gasket to the head cover gasket at the corners of the recess.
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 57: Applying Liquid Gasket To Head Cover Gasket
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
Use liquid gasket, loctite No. 5999.
Check that the mating surfaces are clean and dry before
applying liquid gasket.
After assembly, wait at least 30 minutes before filling the engine
with oil.
3. Install the cylinder head cover (A) with the 12 bolts (B). Uniformly tighten the bolts in several
passes.
Tightening torque:
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 58: Installing Cylinder Head Cover
Courtesy of KIA MOTORS AMERICA, INC.
11.
12.
13.
14.
15.
Install the PCV (Positive Crankcase Ventilation) hose. (Refer to INSTALLATION , step 2))
Install the timing belt. (Refer to INSTALLATION , step 4-21)
Install the intake manifold. (Refer to INTAKE AND EXHAUST SYSTEM - 2.0L )
Install the exhaust manifold. (Refer to INTAKE AND EXHAUST SYSTEM - 2.0L )
Install the spark plug cables.
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2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 59: Installing Spark Plug Cables
Courtesy of KIA MOTORS AMERICA, INC.
16. Install the power steering pump bracket (A) and bolts (B, C).
Tightening torque:
Bolt (B): 34.3 ~ 49.0N.m (3.5~ 5.0kgf.m, 25.3 ~ 36.2lb-ft)
Bolt (C): 11.8 ~ 14.7N.m (1.2 ~ 1.5kgf.m, 8.7 ~ 10.8lb-ft)
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 60: Installing Power Steering Pump Bracket
Courtesy of KIA MOTORS AMERICA, INC.
17. Install the power steering pump. (See MECHANICAL POWER STEERING SYSTEM )
18. Install the accelerator cable.
19. Install the brake booster hose (A).
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 61: Installing Brake Booster Hose
Courtesy of KIA MOTORS AMERICA, INC.
20. Connect the hose (A) of the PCSV (Purge Control Solenoid Valve) side.
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 62: Connecting Purge Control Solenoid Valve Side Hose
Courtesy of KIA MOTORS AMERICA, INC.
21. Connect the fuel inlet hose (A) of the delivery pipe side.
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 63: Connecting Delivery Pipe Side Fuel Inlet Hose
Courtesy of KIA MOTORS AMERICA, INC.
22. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake
manifold.
1. Connect the PCSV (Purge Control Solenoid Valve) connector (A).
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 64: Connecting Purge Control Solenoid Valve Connector
Courtesy of KIA MOTORS AMERICA, INC.
2. Connect the front heated oxygen sensor connector (A).
3. Connect the CKP (Crankshaft Position Sensor) connector (B).
4. Connect the oil pressure switch connector (C).
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 65: Connecting Oil Pressure Switch Connector
Courtesy of KIA MOTORS AMERICA, INC.
5.
6.
7.
8.
9.
Connect the air conditioner compressor switch connector (E).
Connect the ground cables (D) to intake manifold.
Connect the knock sensor connector (C).
Connect the fuel injector connectors (B).
Connect the CMP (Camshaft position sensor) connector (A).
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 66: Connecting Camshaft Position Sensor Connector
Courtesy of KIA MOTORS AMERICA, INC.
10. Connect the ISA (Idle Speed Actuator) connector (B).
11. Connect the TPS (Throttle Position Sensor) connector (A).
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 67: Connecting Throttle Position Sensor Connector
Courtesy of KIA MOTORS AMERICA, INC.
12.
13.
14.
15.
Connect the ignition coil connector (D).
Connect the ECT (Engine Coolant Temperature) connector (C).
Connect the oil temperature sensor connector (B).
Connect the OCV (Oil Control Valve) connector (A).
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 68: Connecting Oil Control Valve Connector
Courtesy of KIA MOTORS AMERICA, INC.
23. Install the heater hose (A).
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 69: Installing Heater Hose
Courtesy of KIA MOTORS AMERICA, INC.
24. Install the upper radiator hose (A) and lower radiator hose (B).
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 70: Installing Upper And Lower Radiator Hose
Courtesy of KIA MOTORS AMERICA, INC.
25. Install the intake air hose and air cleaner assembly.
1. Install the intake air hose, air cleaner assembly (C) and bolts.
Tightening torque:
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
2. Install the breather hose (B) to intake air hose.
3. Connect the AFS (Air Flow Sensor) connector (A).
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 71: Connecting Air Flow Sensor Connector
Courtesy of KIA MOTORS AMERICA, INC.
26. Install the engine cover.
Tightening torque:
3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)
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2005 Kia Sportage EX
2005-06 ENGINE Cylinder Head Assembly - 2.0L - Sportage
Fig. 72: Installing Engine Cover
Courtesy of KIA MOTORS AMERICA, INC.
27. Reconnect the battery terminals (A).
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Fig. 73: Connecting Battery Terminals
Courtesy of KIA MOTORS AMERICA, INC.
28. Install the air duct (A).
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Fig. 74: Installing Air Duct
Courtesy of KIA MOTORS AMERICA, INC.
29. Fill with engine coolant.
30. Start the engine and check for leaks.
31. Recheck engine coolant level and oil level.
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Page 79
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
2005-06 ENGINE
Engine Block - 2.0L - Sportage
COMPONENT
Fig. 1: Exploded View Of Engine Block Components (1 Of 2)
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08:33:44 a. m.
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2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
Courtesy of KIA MOTORS AMERICA, INC.
Fig. 2: Exploded View Of Engine Block Components (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
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Page 2
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2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
DISASSEMBLY
1.
2.
3.
4.
5.
6.
M/T: Remove the fly wheel.
A/T: Remove the drive plate.
Install the engine block onto an engine stand for disassembly.
Remove the timing belt. (Refer to TIMING BELT REPLACEMENT - 2.0L - DOHC )
Remove the cylinder head. (Refer to CYLINDER HEAD ASSEMBLY - 2.0L )
Remove the oil level gauge tube (A).
Fig. 3: Removing Oil Level Gauge Tube
Courtesy of KIA MOTORS AMERICA, INC.
7. Remove the knock sensor (A).
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2005-06 ENGINE Engine Block - 2.0L - Sportage
Fig. 4: Removing Knock Sensor
Courtesy of KIA MOTORS AMERICA, INC.
8. Remove the oil pressure switch (A).
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2005-06 ENGINE Engine Block - 2.0L - Sportage
Fig. 5: Removing Oil Pressure Switch
Courtesy of KIA MOTORS AMERICA, INC.
9. Remove the water pump. (Refer to WATER PUMP )
10. Remove the oil pan (A).
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2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
Fig. 6: Removing Oil Pan
Courtesy of KIA MOTORS AMERICA, INC.
11. Remove the oil screen.
Remove the 2bolts (C), oil screen (A) and gasket (B).
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2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
Fig. 7: Oil Screen And Gasket
Courtesy of KIA MOTORS AMERICA, INC.
12. Check the connecting rod end play. (Refer to INSPECTION step 1 )
13. Remove the connecting rod caps and check oil clearance. (Refer to INSPECTION INSPECTION step
2)
14. Remove the piston and connecting rod assemblies.
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
NOTE:
Keep the bearings, connecting rod and cap together.
Arrange the piston and connecting rod assemblies in the correct
order.
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Page 7
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2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
15. Remove the front case. (Refer to DISASSEMBLY step 8-9)
16. Remove the rear oil seal case.
Remove the 5bolts (B) and rear oil seal case (A).
Fig. 8: Removing Rear Oil Seal Case
Courtesy of KIA MOTORS AMERICA, INC.
17. Remove the crankshaft bearing cap and check oil clearance. (Refer to INSPECTION step 4 )
18. Check the crankshaft end play. (Refer to INSPECTION step 5 )
19. Lift the crankshaft (A) out of the engine, being careful not to damage journals.
NOTE:
Arrange the main bearings and thrust bearings in the correct order.
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2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
Fig. 9: Removing Crankshaft From Engine
Courtesy of KIA MOTORS AMERICA, INC.
20. Check fit between piston and piston pin.
Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and
pin as a set.
21. Remove the piston rings.
1. Using a piston ring expender, remove the 2 compression rings.
2. Remove the 2 side rails and oil ring by hand.
NOTE:
Arrange the piston rings in the correct order only.
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2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
22. Remove the connecting rod from the piston.
Using a press, remove the piston pin from piston. (Press-in load: 350 ~ 1,350kg(772~2,976lb))
INSPECTION
CONNECTING ROD AND CRANKSHAFT
1. Check the connecting rod end play.
Using feeler gauge, measure the end play while moving the connecting rod back and forth.
End play
Standard: 0.1 ~ 0.25mm (0.0039 ~ 0.0098in)
Maximum: 0.4mm (0.0157in)
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Fig. 10: Measuring Connecting Rod End Play
Courtesy of KIA MOTORS AMERICA, INC.
If out-of-tolerance, install a new connecting rod.
If still out-of-tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance.
1. Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly.
2. Remove the 2 connecting rod cap nuts.
3. Remove the connecting rod cap and lower bearing.
4. Clean the crankshaft pin journal and bearing.
5. Place a plastigage across the crankshaft pin journal.
6. Reinstall the lower bearing and cap, and tighten the nuts.
Tightening torque:
49.0 ~ 52.ON.m (5.0 ~ 5.3kgf.m, 36.2 ~ 38.3lb-ft)
NOTE:
Do not turn the crankshaft.
7. Remove the 2nuts, connecting rod cap and lower bearing.
8. Measure the plastigage at its widest point.
Standard oil clearance
0.024 ~ 0.044mm (0.0009 ~ 0.0017in)
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Fig. 11: Measuring Plastigage At Widest Point
Courtesy of KIA MOTORS AMERICA, INC.
9. If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then
install a new bearings with the same color mark. (Refer to CONNECTING ROD BEARING
SELECTION TABLE )
Recheck the oil clearance.
CAUTION: Do not file, shim, of scrape the bearings or the caps to adjust
clearance.
10. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. (Refer
to CONNECTING ROD BEARING SELECTION TABLE ) Recheck the oil clearance.
NOTE:
If the proper clearance cannot be obtained by using the appropriate
larger or smaller bearings, replace the crankshaft and start over.
CAUTION: If the alignment marks are unreadable because of an
accumulation of grease or grime, don't clean with a wire or
abrasive cleaner. Clean only with correct cleaning solvent or
detergent.
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Page 12
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2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
Fig. 12: Identifying Connecting Rod Mark Location
Courtesy of KIA MOTORS AMERICA, INC.
Discrimination of connecting rod
CONNECTING ROD DISCRIMINATION DETAILS
Mark Connecting rod big-end inner diameter
48.000 ~ 48.006mm
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2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
A
B
C
(1.8898 ~ 1.8900in)
48.006 ~ 48.012mm
(1.8900 ~ 1.8902in)
48.012 ~ 48.018mm
(1.8902 ~ 1.8905in)
Fig. 13: Identifying Crankshaft Pin Journal Mark Location
Courtesy of KIA MOTORS AMERICA, INC.
Discrimination of crankshaft pin journal
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Page 14
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2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
CRANKSHAFT PIN JOURNAL DISCRIMINATION DETAILS
Mark Crankshaft pin journal outer diameter
44.960 ~ 44.966mm
1
(1.7701 ~ 1.7703in)
44.952 ~ 44.960mm
2
(1.7698 ~ 1.7701 in)
44.946 ~ 44.952mm
3
(1.7695 ~ 1.7698in)
Fig. 14: Identifying Connecting Rod Bearing Mark Location
Courtesy of KIA MOTORS AMERICA, INC.
Discrimination of connecting rod bearing
CONNECTING ROD BEARING DISCRIMINATION DETAILS
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2005-06 ENGINE Engine Block - 2.0L - Sportage
Mark Color Connecting rod bearing thickness
1.514 ~ 1.517mm
AA Blue
(0.0596 ~ 0.0597in)
1.511 ~ 1.514mm
A Black
(0.0595 ~ 0.0596in)
1.508 ~ 1.511mm
B None
(0.0594 ~ 0.0595in)
1.505 ~ 1.508mm
C Green
(0.0593 ~ 0.0594in)
1.502 ~ 1.505mm
D Yellow
(0.0591 ~ 0.0593in)
11. Select the bearing by using selection table.
Connecting rod bearing selection table
CONNECTING ROD BEARING SPECIFICATIONS
Connecting rod mark
A (White) B (None) C (Yellow)
1 (Yellow) D (Yellow) C (Green) B (None)
Crank shaft pin journal mark 2 (None) C (Green) B (None) A (Black)
3 (White) B (None) A (Black) AA (Blue)
3. Check the connecting rods.
1. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at
disassembly match. When a new connecting rod is installed, make sure that the notches for holding
the bearing in place are on the same side.
2. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a
severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced
as well.
3. Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is
close to the repair limit, correct the rod by a press. Any connecting rod that has been severely bent
or distorted should be replaced.
Allowable bend of connecting rod:
0.05mm / 100mm (0.0020in / 3.94in ) or less
Allowable twist of connecting rod:
0.1mm / 100mm (0.0039in / 3.94in) or less
4. Check the crankshaft bearing oil clearance.
1. To check main bearing-to-journal oil clearance, remove the main bearing caps and lower bearings.
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2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
2. Clean each main journal and lower bearing with a clean shop towel.
3. Place one strip of plastigage across each main journal.
4. Reinstall the lower bearings and caps, then tighten the bolts.
Tightening torque: 27.5 ~ 31.4N.m
(2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-ft)+60°~ 64°
NOTE:
Do not turn the crankshaft.
5. Remove the cap and lower bearing again, and measure the widest part of the plastigage.
Standard oil clearance:
0.028 ~ 0.048mm (0.0011 ~ 0.0019in)
Fig. 15: Measuring Widest Part Of Plastigage
Courtesy of KIA MOTORS AMERICA, INC.
6. If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then
install a new bearings with the same color mark. (Refer to step 8 )
Recheck the oil clearance.
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CAUTION: Do not file, shim, or scrape the bearings or the cap to adjust
clearance.
7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. (Refer
to step 8 )
Recheck the oil clearance.
NOTE:
If the proper clearance cannot be obtained by using the appropriate
larger or smaller bearings, replace the crankshaft and start over.
CAUTION: If the alignment marks are unreadable because of accumulation
of grease or grime, don't clean with a wire or abrasive cleaner.
Clean only with correct cleaning solvent or detergent.
Cylinder block crankshaft journal bore mark location
Letters have been stamped on the end of the block as a mark for the size of each of the 5 main
journal bores.
Use them, and the numbers or letters stamped on the crank (marks for main journal size), to choose
the correct bearings.
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2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
Fig. 16: Locating Letters Stamped On Crank
Courtesy of KIA MOTORS AMERICA, INC.
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2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
Discrimination of cylinder block crankshaft journal bore
CYLINDER BLOCK CRANKSHAFT JOURNAL BORE DISCRIMINATION DETAILS
Mark Cylinder block crankshaft journal boreinner diameter
61.000 ~ 61.006mm
A
(2.4016 ~ 2.4018in)
61.006 ~ 61.012mm
B
(2.4018 ~ 2.4020in)
61.012 ~ 61.018mm
C
(2.4020 ~ 2.4023in)
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Page 20
© 2011 Mitchell Repair Information Company, LLC.
2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
Fig. 17: Identifying Crankshaft Main Journal Mark Location (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Fig. 18: Identifying Crankshaft Main Journal Mark Location (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Discrimination of crankshaft main journal
CRANKSHAFT MAIN JOURNAL DISCRIMINATION DETAILS
Mark Color Crankshaft main journal outer diameter
56.956 ~ 56.962mm
1 Yellow
(2.2424 ~ 2.2426in)
56.948 ~ 56.956mm
2
None
(2.2420 ~ 2.2424in)
56.942 ~ 56.948mm
3 White
(2.2418 ~ 2.2420in)
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2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
Fig. 19: Identifying Crankshaft Main Bearing Mark Location
Courtesy of KIA MOTORS AMERICA, INC.
Discrimination of crankshaft main bearing
CRANKSHAFT MAIN BEARING DISCRIMINATION DETAILS
Mark Color Crankshaft main bearing thickness
2.014 ~ 2.017mm
AA Blue
(0.0793 ~ 0.0794in)
2.011 ~ 2.014mm
A Black
(0.0792 ~ 0.0793in)
2.008 ~ 2.011mm
B None
(0.0791 ~ 0.0792in)
2.005 ~ 2.008mm
C Green
(0.0789 ~ 0.0791 in)
2.002 ~ 2.005mm
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2005 Kia Sportage EX
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D
Yellow
(0.0788 ~ 0.0789in)
8. Select the bearing by using selection table.
Crankshaft main bearing selection table
CRANKSHAFT MAIN BEARING SPECIFICATIONS
Cylinder block crankshaft journal bore mark
A
B
C
1 (Yellow) D (Yellow)
C (Green)
B (None)
Crank shaft main journal mark 2 (None)
C (Green)
B (None)
A (Black)
3 (White)
B (None)
A (Black)
AA (Blue)
5. Check the crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a
screwdriver.
End play
Standard: 0.06 ~ 0.26mm (0.0024 ~ 0.0102in)
Limit: 0.30mm (0.0118in)
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2005 Kia Sportage EX
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Fig. 20: Measuring Crankshaft End Play
Courtesy of KIA MOTORS AMERICA, INC.
If the end play is greater than maximum, replace the thrust bearings as a set.
Thrust bearing thickness:
2.44 ~ 2.77mm (0.0961 ~ 0.0972in)
6. Inspect the crankshaft main journals and pin journals. Using a micrometer, measure the diameter of each
main journal and pin journal.
Main journal diameter:
56.942 ~ 56.962mm (2.2418 ~ 2.2426in)
Pin journal diameter:
44.946 ~ 44.966mm (1.7695 ~ 1.7703in)
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Fig. 21: Measuring Main Journal Diameter
Courtesy of KIA MOTORS AMERICA, INC.
CYLINDER BLOCK
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2005-06 ENGINE Engine Block - 2.0L - Sportage
1. Remove the gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean the cylinder block.
Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect the top surface of cylinder block for flatness. Using a precision straight edge and feeler gauge,
measure the surface contacting the cylinder head gasket for warpage.
Flatness of cylinder block gasket surface
Total: Less than 0.05mm (0.0020in)
Bore to bore: Less than 0.03mm (0.0012in)
Fig. 22: Inspecting Cylinder Block Gasket Surface Flatness
Courtesy of KIA MOTORS AMERICA, INC.
4. Inspect the cylinder bore.
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2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block.
5. Inspect the cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial
direction.
Standard diameter:
82.00 ~ 82.03mm (3.2283 ~ 3.2295in)
Fig. 23: Measuring Cylinder Bore Diameter
Courtesy of KIA MOTORS AMERICA, INC.
6. Check the cylinder bore size code on the cylinder block bottom face.
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Fig. 24: Checking Cylinder Bore Size Code On Cylinder Block Bottom Face
Courtesy of KIA MOTORS AMERICA, INC.
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Discrimination of cylinder bore size
CYLINDER BORE SIZE DISCRIMINATION DETAILS
Mark Cylinder bore inner diameter
82.00 ~ 82.01mm
A
(3.2283 ~ 3.2287in)
82.01 ~ 82.02mm
B
(3.2287 ~ 3.2291 in)
82.02 ~ 82.03mm
C
(3.2291 ~ 3.2295in)
7. Check the piston size mark (A) on the piston top face.
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2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
Fig. 25: Checking Piston Size Mark On Piston Top Face
Courtesy of KIA MOTORS AMERICA, INC.
Discrimination of piston outer diameter
PISTON OUTER DIAMETER DISCRIMINATION DETAILS
Mark Piston outer diameter
81.97 ~ 81.98mm
A
(3.2272 ~ 3.2276in)
81.98 ~ 81.99mm
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None (3.2276 ~ 3.2279in)
81.99 ~ 82.00mm
C
(3.2279 ~ 3.2283in)
8. Select the piston related to cylinder bore class.
Piston-to-cylinder clearance:
0.02 ~ 0.04mm (0.0008 ~ 0.0016in)
BORING CYLINDER
1. Oversize pistons should be selected according to the largest bore cylinder.
NOTE:
The size of piston is stamped on top of the piston.
2. Measure the outside diameter of the piston to be used.
3. According to the measured O.D (Outer Diameter), calculate the new bore size.
New bore size = piston O.D + 0.02 to 0.04mm (0.0008 to 0.0016in) (Clearance between piston and
cylinder) - 0.01mm (0.0004in) (honing margin.)
4. Bore each of the cylinders to the calculated size.
CAUTION: To prevent distortion that may result from temperature rise during
honing, bore the cylinder holes in the firing order.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter+gap with cylinder).
6. Check the clearance between the piston and cylinder.
Standard: 0.02 ~ 0.04mm (0.0008 ~ 0.0016in)
NOTE:
When boring the cylinders, finish all of the cylinders to the same oversize.
Do not bore only one cylinder to the oversize.
PISTON AND PISTON RINGS
1. Clean the piston.
1. Using a gasket scraper, remove the carbon from the piston top.
2. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
3. Using solvent and a brush, thoroughly clean the piston.
NOTE:
Do not use a wire brush.
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2. The standard measurement of the piston outside diameter is taken 47mm (1.85in) from top land of the
piston.
Standard diameter:
81.97 ~ 82.00mm (3.2272 ~ 3.2283in)
Fig. 26: Measuring Piston Outside Diameter
Courtesy of KIA MOTORS AMERICA, INC.
3. Calculate the difference between the cylinder bore inner diameter and the piston outer diameter.
Piston-to-cylinder clearance:
0.02 ~ 0.04mm (0.0008 ~ 0.0016in)
4. Inspect the piston ring side clearance.
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2005-06 ENGINE Engine Block - 2.0L - Sportage
Using a feeler gauge, measure the clearance between new piston ring and the wall of ring groove.
Piston ring side clearance
No.1: 0.04 ~ 0.08mm (0.0016 ~ 0.0031 in)
No. 2: 0.03 ~ 0.07mm (0.0012 ~ 0.0028in)
Oil ring: 0.06 ~ 0.15mm (0.0024 ~ 0.0059in)
Limit
No.1: 0.1mm (0.0039in)
No.2: 0.1mm (0.0039in)
Oil ring: 0.2mm (0.0079in)
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Fig. 27: Measuring Piston Ring Side Clearance
Courtesy of KIA MOTORS AMERICA, INC.
If the clearance is greater than maximum, replace the piston.
5. Inspect the piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right
angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge.
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2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
If the gap exceeds the service limit, replace the piston rings. If the gap is too large, recheck the cylinder
bore inner diameter. If the bore is over the service limit, the cylinder block must be rebored. (Refer to
BORING CYLINDER )
Piston ring end gap
Standard
No.1: 0.23 ~ 0.38mm (0.0091 ~ 0.0150in)
No.2: 0.33 ~ 0.48mm (0.0130 ~ 0.0189in)
Oil ring: 0.20 ~ 0.60mm(0.0079 ~ 0.0236in)
Limit
No.1, 2, oil ring: 1.0mm(0.039in)
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Fig. 28: Inspecting Piston Ring End Gap
Courtesy of KIA MOTORS AMERICA, INC.
PISTON PINS
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2005 Kia Sportage EX
2005-06 ENGINE Engine Block - 2.0L - Sportage
1. Measure the outer diameter of piston pin.
Piston pin diameter:
20.001 ~ 20.006mm (0.7874 ~ 0.7876in)
Fig. 29: Measuring Piston Pin Outer Diameter
Courtesy of KIA MOTORS AMERICA, INC.
2. Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance:
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0.01 ~ 0.02mm (0.0004 ~ 0.0008in)
3. Check the difference between the piston pin outer diameter and the connecting rod small end inner
diameter.
Piston pin-to-connecting rod interference:
-0.032 ~ -0.016mm (-0.0013 ~ -0.0006in)
OIL PRESSURE SWITCH
1. Check the continuity between the terminal and the body with an ohmmeter. If there is no continuity,
replace the oil pressure switch.
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2005-06 ENGINE Engine Block - 2.0L - Sportage
Fig. 30: Checking Continuity Between Oil Pressure Switch Terminal And Body (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is
continuity even when the fine wire is pushed, replace the switch.
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2005-06 ENGINE Engine Block - 2.0L - Sportage
Fig. 31: Checking Continuity Between Oil Pressure Switch Terminal And Body (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
3. If there is no continuity when a 49.0kpa (0.5kg/cm2 , 7.1 psi) vacuum is applied through the oil hole, the
switch is operating properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace it.
REASSEMBLY
NOTE:
Thoroughly clean all parts to assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating
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2005-06 ENGINE Engine Block - 2.0L - Sportage
surfaces.
Replace all gaskets, O-rings and oil seals with new parts.
1. Assemble the piston and connecting rod.
1. Use a hydraulic press for installation
2. The piston front mark and the connecting rod front mark must face the timing belt side of the
engine.
Fig. 32: Assembling Piston And Connecting Rod
Courtesy of KIA MOTORS AMERICA, INC.
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2. Install the piston rings.
1. Install the oil ring spacer and 2 side rails by hand.
2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
3. Position the piston rings so that the ring ends are as shown.
Fig. 33: View Of Piston Ring
Courtesy of KIA MOTORS AMERICA, INC.
3. Install the connecting rod bearings.
1. Align the bearing claw with the groove of the connecting rod or connecting rod cap.
2. Install the bearings (A) in the connecting rod and connecting rod cap (B).
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2005-06 ENGINE Engine Block - 2.0L - Sportage
Fig. 34: Installing Connecting Rod Bearings
Courtesy of KIA MOTORS AMERICA, INC.
4. Install the crankshaft main bearings.
NOTE:
Upper 1, 2, 4, 5 bearings have an oil groove of oil holes; Lower bearings do
not.
1. Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings
(A).
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Fig. 35: Installing Crankshaft Main Bearings
Courtesy of KIA MOTORS AMERICA, INC.
2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower
bearings.
5. Install the thrust bearings.
Install the 2 thrust bearings (A) under the No.3 journal position of the cylinder block with the oil grooves
facing outward.
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Fig. 36: Installing Thrust Bearings
Courtesy of KIA MOTORS AMERICA, INC.
6. Place the crankshaft on the cylinder block.
7. Place the main bearing caps on the cylinder block.
8. Install the main bearing cap bolts.
NOTE:
The main bearing cap bolts are tightened in 2 progressive steps.
If any of the bearing cap bolts in broken or deformed, replace it.
1. Apply a light coat of engine oil on the threads and under the bearing cap bolts.
2. Install and uniformly tighten the 10 bearing cap bolts (A), in several passes, in the sequence shown.
Tightening torque: 27.5 ~ 31.4N.m
(2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-ft) + 60°~ 64°
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Fig. 37: Installing Main Bearing Cap Bolts
Courtesy of KIA MOTORS AMERICA, INC.
3. Check that the crankshaft turns smoothly.
9. Check the crankshaft end play. (Refer to INSPECTION step 5
10. Install the piston and connecting rod assemblies.
NOTE:
Before installing the piston, apply a coat of engine oil to the ring grooves
and cylinder bores.
1. Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of
the connecting rod bolts
2. Install the ring compressor, check that the rings are securely in place, then position the piston in the
cylinder, and tap it in using the wooden handle of a hammer.
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3. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment
before pushing the piston into place.
4. Apply engine oil to the bolt threads, install the rod caps with bearings, and tighten the nuts.
Tightening torque:
49.0 ~ 52.0N.m (5.0 ~ 5.3kgf.m, 36.2 ~ 38.3lb-ft)
NOTE:
Maintain downward force on the ring compressor to prevent the rings from
expending before entering the cylinder bore.
Fig. 38: [Installing Piston Ring Compressor]
Courtesy of KIA MOTORS AMERICA, INC.
11. Install a new gasket and rear oil seal case (A) with 5 bolts (B).
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Tightening torque:
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Fig. 39: Installing Gasket And Rear Oil Seal Case
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
Check that the mating surfaces are clean and dry.
12. Install the rear oil seal.
1. Apply engine oil to a new oil seal lip.
2. Using the SST(09231 -21000) and a hammer, tap in the oil seal until its surface is flush with the
rear oil seal retainer edge.
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Fig. 40: Installing Rear Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
13. Install the front case. (Refer to INSTALLATION step 1~5)
14. Install the oil screen.
Install a new gasket (B) and oil screen (A) with 2 bolts (C).
Tightening torque:
14.7 ~ 21.6N.m (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)
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2005-06 ENGINE Engine Block - 2.0L - Sportage
Fig. 41: Installing Oil Screen And Gasket
Courtesy of KIA MOTORS AMERICA, INC.
15. Install the oil pan.
1. Using a razor blade and gasket scraper, remove all the old packing material from the gasket
surfaces.
NOTE:
Check that the mating surfaces are clean and dry before applying
liquid gasket.
2. Apply liquid gasket as an even bead, centered between the edges of the mating surface.
Liquid gasket: MS 721-40A or equivalent
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NOTE:
To prevent leakage of oil, apply liquid gasket to the inner
threads of the bolt holes.
Do not install the parts if five minutes or more have elapsed
since applying the liquid gasket. Instead, reapply liquid gasket
after removing the residue.
After assembly, wait at least 30 minutes before filling the engine
with oil.
3. Install the oil pan (A) with the bolts.
Uniformly tighten the bolts in several passes.
Tightening torque:
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Fig. 42: Installing Oil Pan
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Courtesy of KIA MOTORS AMERICA, INC.
16. Install the water pump. (Refer to WATER PUMP )
17. Install the oil pressure switch.
1. Apply adhesive to 2 or 3 threads.
Adhesive: MS 721 -39 (B) or equivalent.
2. Install the oil pressure switch (A).
Tightening torque:
14.7 ~ 21.6N.m (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)
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Fig. 43: Installing Oil Pressure Switch
Courtesy of KIA MOTORS AMERICA, INC.
18. Install the knock sensor (A).
Tightening torque:
16.7 ~ 26.5N.m (1.7 ~ 2.7kgf.m, 12.3 ~ 19.5lb-ft)
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Fig. 44: Installing Knock Sensor
Courtesy of KIA MOTORS AMERICA, INC.
19. Install the oil level gauge tube (A).
1. Install a new O-ring on the oil level gauge tube.
2. Apply engine oil on the O-ring.
3. Install the oil level gauge tube (A) with the bolt.
Tightening torque:
11.8 ~ 14.7N.m (1.2 ~ 1.5kgf.m, 8.7 ~ 10.8lb-ft)
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Fig. 45: Installing Oil Level Gauge Tube
Courtesy of KIA MOTORS AMERICA, INC.
20.
21.
22.
23.
Install the cylinder head. (Refer to CYLINDER HEAD ASSEMBLY - 2.0L )
Install the timing belt. (Refer to TIMING BELT REPLACEMENT - 2.0L - DOHC )
Remove the engine stand.
A/T: install the drive plate (A) and washer (B).
Tightening torque:
117.7 ~ 127.5N.m (12.0 ~ 13.0kgf.m, 86.8 ~ 94.0lb-ft)
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Fig. 46: Installing Drive Plate And Washer (A/T)
Courtesy of KIA MOTORS AMERICA, INC.
24. M/T: install the fly wheel.
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Tightening torque:
117.7 ~ 127.5N.m (12.0 ~ 13.0kgf.m, 86.8 ~ 94.0lb-ft)
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